Modular heat exchangers

ABSTRACT

The subject matter of this specification can be embodied in, among other things, a heat exchanger module that includes a tubular housing, a first fluid conduit, a second fluid conduit, fluidically isolated from the first fluid conduit, a thermal conductor configured to convey heat energy between the first fluid conduit and the second fluid conduit, a first fluid connector assembly, the first fluid connector assembly having a first fluid port fluidically connected to the first fluid conduit, and a second fluid port fluidically connected to the second fluid conduit, and a second fluid connector assembly, the second fluid connector assembly having a third fluid port fluidically connected to the first fluid conduit, and a fourth fluid port fluidically connected to the second fluid conduit.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Patent Application No. 63/300,432, filed Jan. 18, 2022, the contents of which are incorporated by reference herein.

TECHNICAL FIELD

This instant specification relates to modular fluid-to-fluid heat exchangers.

BACKGROUND

A heat exchanger is an apparatus that is used to transfer heat between two or more fluids. In indirect-contact types of heat exchangers, the hot and cold fluids are separated by an impervious surface.

Some types of heat exchangers include shell-and-tube or plate-and-fin designs, depending on the specific application, customer requirements, and operating parameters. In such designs and other previous designs, the heat exchanger is an assembly of multiple tubes/conduits and fins/plates that are brazed, soldered, welded, or otherwise joined together. In general, complexity of such designs further increases as heat transfer and/or flow capacity requirements increase. Such assemblies include large numbers of joints that can fatigue, wear, or otherwise eventually lead to leaks and/or failure. The complexity of such designs also makes it difficult or economically impractical to repair them.

SUMMARY

In general, this document describes modular fluid-to-fluid heat exchangers.

In a first example, a heat exchanger module includes a tubular housing, a first fluid conduit, a second fluid conduit fluidically isolated from the first fluid conduit, a thermal conductor configured to convey heat energy between the first fluid conduit and the second fluid conduit, a first fluid connector assembly, the first fluid connector assembly having a first fluid port fluidically connected to the first fluid conduit, and a second fluid port fluidically connected to the second fluid conduit, and a second fluid connector assembly, the second fluid connector assembly having a third fluid port fluidically connected to the first fluid conduit, and a fourth fluid port fluidically connected to the second fluid conduit.

Various embodiments can include some, all, or none of the following features. The first fluid conduit can be a first tubular conduit defined within the tubular housing, and the second fluid conduit can be a second tubular conduit defined concentrically within the first fluid conduit. The first fluid conduit can include one or more supply channels, a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and one or more drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the third fluid port. The second fluid conduit can include one or more supply channels, a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and one or more drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the fourth fluid port. The heat exchanger module can include at least one fluid connector assembly having a first fluid port fluidically connected to the first fluid conduit, a second fluid port configured fluidically connected to the second fluid conduit, and a seal assembly having an interface defining a first fluid seal arranged between the first fluid port and the second fluid port. The heat exchanger module can include a second fluid seal defined between the first fluid port and the second fluid port, wherein a first fluid connector assembly can be configured to removably connect to a first fluid coupler of a first manifold assembly, to fluidically connect the first fluid conduit to a first fluid manifold of the first manifold assembly and to connect the second fluid conduit to a second fluid manifold of the first manifold assembly, and a second fluid connector assembly can be configured to removably connect to a second fluid coupler of a second manifold assembly, to fluidically connect the first fluid conduit to a third fluid manifold of the second manifold assembly and fluidically connect the second fluid conduit to a fourth fluid manifold of the second manifold assembly. The first manifold assembly can define an overboard fluid path fluidically connecting a cavity between the first fluid seal and the second fluid seal of the first fluid connector assembly to a fluid drain. The second manifold assembly can define an overboard fluid path fluidically connecting a cavity between the first fluid seal and the second fluid seal of the second fluid connector assembly to a fluid drain.

In another example embodiment, a modular heat exchanger assembly includes a first manifold assembly having a first manifold and a second manifold, a second manifold assembly having a third manifold and a fourth manifold, and at least one heat exchanger module configured to removably engage the first manifold assembly and the second manifold assembly and having a tubular housing, a first fluid conduit, a second fluid conduit, fluidically isolated from the first fluid conduit, and a thermal conductor configured to convey heat energy between the first fluid conduit and the second fluid conduit.

Various embodiments can include some, all, or none of the following features. The first manifold assembly can include a first manifold fluid port fluidically connected to the first manifold and a second manifold fluid port fluidically connected to the second manifold. The heat exchanger module can include a fluid connector assembly, the fluid connector assembly having a first fluid connector assembly, the first fluid connector assembly having a first fluid port fluidically connected to the first fluid conduit and configured to fluidically connect the first fluid conduit to the first manifold assembly, and a second fluid port fluidically connected to the second fluid conduit configured to fluidically connect the second fluid conduit to the second manifold assembly, and a second fluid connector assembly, the second fluid connector assembly having a third fluid port fluidically connected to the first fluid conduit and configured to fluidically connect the first fluid conduit to the third manifold, and a fourth fluid port fluidically connected to the second fluid conduit configured to fluidically connect the second fluid conduit to the fourth manifold. The first fluid connector assembly can define a first seal defined between the first fluid port and the second fluid port, and the first manifold assembly can define a first overboard fluid path fluidically connecting a first cavity defined between the first seal, the second fluid conduit, and the first manifold assembly to a first drain. The modular heat exchanger assembly can include a second seal defined between the first fluid port and the second fluid port, wherein the second fluid connector assembly defines a third seal and a fourth seal arranged between the third fluid port and the fourth fluid port, and the second manifold assembly defines a second overboard fluid path fluidically connecting a second cavity defined between the third seal, the fourth seal, the second fluid conduit, and the second manifold assembly to a second drain. The first fluid conduit can be a first tubular conduit defined within the tubular housing, and the second fluid conduit can be a second tubular conduit defined concentrically within the first fluid conduit. The first fluid conduit can include one or more supply channels, a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and a collection of drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the third manifold. The second fluid conduit can include one or more supply channels, a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and a collection of drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the fourth manifold.

In an example implementation, a method of heat exchange includes flowing a first flow of a first fluid to a first manifold assembly, directing, by the first manifold assembly, the first flow to at least one modular heat exchanger assembly coupled to the first manifold assembly, flowing a second flow of a second fluid to a second manifold assembly removably coupled to the at least one modular heat exchanger assembly, directing, by the second manifold assembly, the second flow to the at least one modular heat exchanger assembly, flowing, through a first fluid conduit of the modular heat exchanger assembly, the first flow from the first manifold assembly to the second manifold assembly, flowing, through a second fluid conduit of the modular heat exchanger assembly, the second flow from the second manifold assembly to the first manifold assembly, and conveying, by a thermal conductor, heat energy between the first fluid and the second fluid.

Various implementations can include some, all, or none of the following features. Flowing, through the first fluid conduit of the modular heat exchanger assembly, the first flow from the first manifold assembly to the second manifold assembly can include flowing the first flow through one or more supply channels of the first fluid conduit, flowing the first flow through a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and flowing the first flow through a collection of drain channels of the first fluid conduit, away from the thermal conductor. Flowing, through the second fluid conduit of the modular heat exchanger assembly, the second flow from the second manifold assembly to the first manifold assembly can include flowing the second flow through one or more supply channels of the second fluid conduit, flowing the second flow through a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and flowing the second flow through a collection of drain channels of the second fluid conduit, away from the thermal conductor. The method can include assembling the modular heat exchanger assembly to the first manifold assembly, fluidically connecting, based on the assembling, the first fluid conduit to a first manifold of the first manifold assembly, fluidically connecting, based on the assembling, the second fluid conduit to a second manifold of the first manifold assembly, assembling the modular heat exchanger assembly to the second manifold assembly, fluidically connecting, based on the assembling, the first fluid conduit to a third manifold of the second manifold assembly, and fluidically connecting, based on the assembling, the second fluid conduit to a fourth manifold of the second manifold assembly. The method can include directing, by a collection of seals configured to separate the first flow from the second flow, leakage of one of the first flow or the second flow past at least one of the collection of seals away from the other of the first flow or the second flow and toward a drain. The systems and techniques described here may provide one or more of the following advantages. First, a system can provide a heat exchanger having a modular design that can ease manufacturing and assembly. Second, the modular nature of the system can improve reparability and reduce maintenance time. Third, the fluid flow and/or heat transfer capacity of the system can be changed by using greater or fewer heat exchanger modules. Fourth, the system can provide flexibility in application, as the arrangements of heat exchanger modules can be varied to suit different installation environments. Fifth, the system can provide greater reliability by having a reduced number of joints that can fatigue and/or leak over time and use. Sixth, the heat exchanger modules can be configured to utilize fluid jet impingement to improve heat transfer capacity.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view that shows an example of a modular heat exchanger assembly.

FIG. 2 is a sectional perspective view of the example modular heat exchanger assembly of FIG. 1 .

FIG. 3 is a perspective view of an example heat exchanger housing.

FIGS. 4A and 4B are perspective views of example fluid manifold assemblies.

FIGS. 5A-5C are various views of an example heat exchanger module.

FIG. 6 is an enlarged sectional side view of a portion of the example modular heat exchanger of FIGS. 1 and 2 .

FIG. 7 is a schematic diagram of an example of a heat exchanger module.

FIGS. 8A-8C show example arrangements of multiple modular heat exchangers.

FIG. 9 shows a schematic example of fluid flows and heat exchange in an example heat exchanger.

FIG. 10 shows a schematic example of fluid flows and heat exchange in an example heat exchanger configured to utilize fluid impingement.

FIG. 11 shows a schematic example of fluid flows and heat exchange in an example heat exchanger configured to utilize dual fluid impingement.

FIG. 12 shows a schematic example of a modular heat exchanger with fluid impingement ports.

FIG. 13 shows another schematic example of another modular heat exchanger with fluid impingement ports.

FIG. 14 is a flow diagram of an example process for heat exchange.

DETAILED DESCRIPTION

This document describes systems and techniques for modular heat exchange. In general, modular heat exchangers can include one or more replaceable/interchangeable heat exchanger modules (e.g., cartridges) that fluidically interface with one or more fluid manifolds to create two or more independent fluid paths for indirect fluid heat transfer. The design of the modules results in a fraction of the seams and joints found in prior heat exchanger designs, to provide a fraction of the potential failure and leakage points found in prior heat exchanger designs. Furthermore, because the modules are replaceable, a modular heat exchanger assembly can be more easily repaired and returned to service (e.g., by replacing a faulty cartridge) than can be done in the more monolithic designs of previous heat exchangers. As will be discussed in more detail below, the performance of some examples of heat exchanger modules can be enhanced through designs that use fluid flows that impinge upon the thermally conductive barriers between the fluids.

FIG. 1 is a perspective view that shows an example of a modular heat exchanger assembly 100. The modular heat exchanger assembly 100 includes a fluid manifold assembly 110 a that is fluidically connected to a fluid manifold assembly 110 b by a heat exchanger portion 130 having an outer housing 132.

In general, the heat exchanger portion 130 is a tubular modular component that is configured to removably connect to the fluid manifold assembly 110 a at one axial end and removably connect to the fluid manifold assembly 110 b at the opposite axial end. The heat exchanger portion 130 is configured to position one or more heat exchanger modules that will be discussed in more detail in the descriptions of FIGS. 2-10 . The heat exchanger modules are configured to perform fluid-to-fluid indirect heat exchange by using two or more fluids provided and/or collected as two or more isolated fluid flows by the fluid manifold assemblies 110 a and 110 b.

The fluid manifold assembly 110 a includes a fluid port 112 a that is fluidically connected by the heat exchanger portion 130 to a fluid port 112 b of the fluid manifold assembly 110 b. The fluid manifold assembly 110 a also includes a manifold port 114 a that is fluidically connected by the heat exchanger portion 130 to a manifold port 114 b of the fluid manifold assembly 110 b. The modular heat exchanger assembly 100 defines a first fluid path (not visible in this view) from the fluid port 112 a, through the heat exchanger portion 130 to the fluid port 112 b, and defines a second fluid path from the manifold port 114 a, through the heat exchanger portion 130 to the manifold port 114 b. The first fluid path and the second fluid path are fluidically isolated from each other within the modular heat exchanger assembly 100 and are configured to perform indirect fluid-to-fluid heat transfer. A drain port 116 provides an overboard drain for internal leakages.

FIG. 2 is a sectional perspective view of the example modular heat exchanger assembly 100 of FIG. 1 . The heat exchanger portion 130 includes a collection of heat exchanger modules 200. In general, each of the heat exchanger modules 200 is a replaceable subassembly (e.g., a cartridge, cassette) that is configured to act as a heat exchanger within the modular heat exchanger assembly 100. When assembled to the fluid manifold assembly 110 a and the fluid manifold assembly 110 b, the heat exchanger modules 200 each define a portion of a first (e.g., fuel) fluid flow path between the fluid ports 112 a and 112 b, and define a portion of a second (e.g., oil, coolant) fluid flow path between the manifold ports 114 a and 114 b. Each of the heat exchanger modules 200 is configured to fluidically isolate the fluid in the first fluid path from the fluid in the second fluid path (e.g., to prevent mixing and/or cross contamination) while facilitating an exchange of thermal energy between the two fluids. Examples of the heat exchanger modules 200 will be discussed further in the descriptions of FIGS. 5A-13 .

FIG. 3 is a perspective view of the example heat exchanger portion 130. The outer housing 132 defines a collection of cavities 300 that are configured to accept insertion of the heat exchanger modules 200. Each of the cavities 300 is defined in part by a cavity wall 302. In some embodiments, the cavity wall 302 can at least partly define part of the fluid path between the fluid ports 112 a and 112 b and/or between the manifold ports 114 a and 114 b.

The outer housing 132 also defines a cavity 310 that, in some embodiments, can provide a fluid bypass path between the fluid ports 112 a and 112 b or between the manifold ports 114 a and 114 b. For example, the fluid manifold assembly 110 a and/or fluid manifold assembly 110 b can include a bypass valve that can open if flow through the heat exchanger portion 130 becomes blocked, and temporarily permit flow around the blockage through the cavity 310 until the blockage can be remedied.

FIG. 4A is a perspective view of the example fluid manifold assembly 110 a. Visible in this view are the manifold ports 112 a and 114 a. The fluid manifold assembly 110 a also includes a fluid connector 410 a. The fluid connector 410 a is configured to interface with and define a fluidic seal with the cavity 310 of the outer housing 132 (e.g., to further define a fluid bypass path). The fluid manifold assembly 110 a also includes a collection of fluid couplers 420, not visible in this view. The fluid couplers 420 will be discussed further in the description of FIG. 4B.

FIG. 4B is a perspective view of the example fluid manifold assembly 110 b. Visible in this view are the manifold ports 112 b and 114 b. The fluid manifold assembly 110 b also includes a fluid connector 410 b. The fluid connector 410 b is configured to interface with and define a fluidic seal with the cavity 310 of the outer housing 132 (e.g., to further define a fluid bypass path).

Visible in this view, the fluid manifold assembly 110 b also includes a collection of fluid couplers 420. Each of the fluid couplers 420 is configured to mate with and fluidically seal with an end of a corresponding heat exchanger module 200. When assembled to an end of one of the heat exchanger modules 200, the fluid coupler 420 defines a part of the fluid flow path between the fluid ports 112 a and 112 b and defines a part of the fluid flow path between the manifold ports 114 a and 114 b. Referring briefly back to FIG. 4A, the example fluid manifold assembly 110 a includes a similar collection of fluid couplers 420, not visible in the view of FIG. 4A.

FIG. 5A is a perspective view of the example heat exchanger module 200 of FIG. 2 . FIG. 5B is an end view of the example heat exchanger module 200, enlarged to show additional detail. FIG. 5C is a sectional side view of the example heat exchanger module 200.

The heat exchanger module 200 has a body 202 that extends from a fluid connector assembly 210 a to a fluid connector assembly 210 b. The fluid connector assemblies 210 a and 210 b are configured to mate with and fluidically seal with fluid connectors of a fluid manifold, such as the example fluid couplers 420 of the example fluid manifold assemblies 110 a and/or 110 b.

The example heat exchanger module 200 includes a collection of fluid conduits 220 that extend from the fluid connector assembly 210 a to the fluid connector assembly 210 b. In the illustrated example, the heat exchanger module 200 includes several of the fluid conduits, but in some embodiments the heat exchanger module 200 can have a single one of the fluid conduits 220, or may have two, three, five, ten, twenty, or any other appropriate number of fluid conduits 220. The heat exchanger module 200 also includes a number of radial fins 230 and radial dividers 240 that extend radially from and encircle the body 202.

FIG. 6 is an enlarged sectional side view of a portion of the example modular heat exchanger assembly 100 of FIGS. 1 and 2 . The heat exchanger module 200 is inserted into or otherwise assembled to a tubular heat exchanger module housing 610, such that the radial dividers 240 contact an inner wall of the housing 610 to position the heat exchanger module 200 within the housing 610 and to at least partly define a fluid conduit 620 between the body 202 and the housing 610. As will be discussed further in the descriptions of FIGS. 7 and 9-13 , in some embodiments the radial dividers 240 can promote heat transfer by directing and/or disrupting fluid flow along the heat exchanger module 200 (e.g., increasing the total length of the flow path, by breaking up laminar flows). In some embodiments, the radial fins 230 can be configured to promote heat transfer by increasing the amount of surface area that is exposed to one or both fluids flowing through the heat exchanger module 200.

When the fluid manifold assembly 110 a is assembled to the heat exchanger portion 130, the fluid connector assemblies 210 a become inserted into the fluid couplers 420, a fluid seal assembly 612 fluidically separates the fluid conduits 620 from the fluid conduits 220, and the fluid conduits 220 are fluidically connected to the fluid port 112 a while the fluid conduits 620 are fluidically connected to the manifold port 114 a. Fluid leakage that manages to get past the fluid seal assembly 612 flows to a collection of drain channels 614 defined in the fluid manifold assembly 110 a, which in turn is fluidically connected to a fluid drain to define an overboard fluid path. In some embodiments, by draining away such leakage, intermixing and/or cross-contamination of the fluids in the fluid conduits 220 and 620 can be prevented.

While not shown in the view provided by FIG. 6 , when the fluid manifold assembly 110 b is assembled to the heat exchanger portion 130, the fluid connector assemblies 210 b become inserted into fluid connectors defined in the fluid manifold that are substantially similar to the fluid couplers 420, a collection of seals arranged substantially similar to the fluid seal assembly 612 fluidically separate the fluid conduits 620 from the fluid conduits 220, and the fluid conduits 220 are fluidically connected to the fluid port 112 b while the fluid conduits 620 are fluidically connected to the manifold port 114 b. Fluid leakage that manages to get past the seals flows to a drain manifold defined in the fluid manifold assembly 110 b. In some embodiments, by draining away such leakage, intermixing and/or cross-contamination of the fluids in the fluid conduits 220 and 620 can be prevented.

FIG. 7 is a schematic diagram of an example of a heat exchanger module 700. In some embodiments, the heat exchanger module 700 can be a visually simplified model of an embodiment of the example heat exchanger module 200 and the example fluid conduits 220 and 620 defined by the heat exchanger module 200 and the example cavity walls 302 of FIGS. 1-6 .

The heat exchanger module 700 includes a fluid conduit 702 (e.g., a tubular conduit) having an inner wall 703 defined through the axial length of the heat exchanger module 700 between an inlet 704 and an outlet 706. When assembled to a heat exchanger portion (e.g., by being inserted into one of the cavities 300 of the example heat exchanger portion 130), a second fluid conduit 712 is defined in part by an outer wall 708 of the fluid conduit 702 and a cavity wall 701 (e.g., another tubular conduit, such as the example cavity wall 302 of FIG. 3 ) between an inlet 714 and an outlet 716. A collection of seals 720 are configured to seal against fluid connectors in fluid manifolds (e.g., the example fluid couplers 420 of the fluid manifold assemblies 110 a and 110 b.

In some embodiments, the selections of inlets, outlets, and directions of flows can implement any appropriate combination. For example, the inlet 704 and/or the inlet 714 can be used as outlets, and the outlet 706 and/or the outlet 716 can be used as inlets.

In use, fluids received at the inlets 704 and 714 from their respective fluid manifolds flow along the fluid conduits 702 and 712 to the outlets 706 and 716 and out through their respective manifold outlets. The outer wall 708 is thermally conductive, so while the fluids in the fluid conduits 702 and 712 are fluidically isolated from each other by the inner wall 703 and the outer wall 708, thermal energy (e.g., heat) is able to pass from one fluid to the other. In the illustrated example, the amount of surface area available for heat transfer is defined by the inner wall 703 and by the outer wall 708.

FIGS. 8A-8C show three example arrangements of multiple heat exchanger modules 820, which in some embodiments can be the example heat exchanger modules 200 of FIGS. 2, 5A-5C, 6, and 7 . In general, by using multiple heat exchanger modules arranged substantially in parallel, various shapes and configurations of heat exchanger assemblies can be provided. For example, the example heat exchanger modules 200 and 820 can be arranged to reduce the total volume of a heat exchanger assembly. In another example, the example heat exchanger modules 200 and 820 can be arranged such that a heat exchanger assembly fits within a predefined volume (e.g., to fit into an available space, to provide clearance for neighboring components).

FIG. 8A shows an example arrangement 800 a, in which eleven of the heat exchanger modules 820 are arranged in a two-layer, planar (e.g., flat pack) arrangement. While eleven heat exchanger modules 820 are shown in the illustrated examples, in some embodiments any appropriate number of heat exchanger modules 820 can be arranged in any appropriate number of layers, with any appropriate horizontal and/or vertical spacing and offset. In some embodiments, flat arrangements could be used in heat exchanger assemblies that are designed to lie flat against or adjacent to a wall, ceiling, or floor of an equipment compartment.

FIG. 8B shows example arrangement 800 b, in which eleven of the heat exchanger modules 820 are arranged in a curved or “profiled” arrangement. In some embodiments, any appropriate number of heat exchanger modules 820 can be arranged in any appropriate number of layers, with any appropriate density, spacing, offset, and/or overall curvature. In some embodiments, curved arrangements could be used in heat exchanger assemblies that are designed to lie flat against or provide space for a tubular or curved external component within the working environment.

FIG. 8C shows an example arrangement 800 c, in which eleven of the heat exchanger modules 820 are arranged in a three-column, semi-rectangular matrix arrangement. In some embodiments, any appropriate number of heat exchanger modules 820 can be arranged in any appropriate number of rows and columns, with any appropriate horizontal and/or vertical spacing and offset. In some embodiments, matrixed arrangements could be used in heat exchanger assemblies that are designed to provide high volumes of heat transfer in a compact space.

FIG. 9 shows a schematic example of fluid flows and heat exchange in an example heat exchanger module 900. In the illustrated example, a fluid flow 901 a flows in a first direction 902 a through a fluid conduit 910 a. A fluid flow 901 b flows in a second direction 902 b, opposite the first direction 902 a, through a fluid conduit 910 b. The fluid flow 901 a and the fluid flow 901 b are separated by a thermal conductor 920 that is configured to conduct heat energy between the fluid flows 901 a, 901 b.

In the illustrated example, the cross-sectional velocities of the fluid flows 901 a, 901 b are represented by a collection of arrows 930, in which longer arrows represent faster flow and shorter arrows represent slower flow. As a fluid flows along a conduit, drag generally occurs at/near the boundaries between the fluid and the solid walls of the conduit. In the illustrated example, the fluid conduits 910 a and 910 b are substantially linear, and have relatively faster flows through their centers while having relatively slower flows near the walls, including along the thermal conductor 920.

In the illustrated example, the portions of the fluid flows 901 a, 901 b proximal the thermal conductor 920 form fluid boundary layers that have little interaction with other portions of their respective flows. As such, the portions of the fluid flows 901 a, 901 b proximal the thermal conductor 920 can reach thermal equilibrium with little additional heat transfer occurring between the portions of the fluid flows 901 a, 901 b that are more distal from the thermal conductor. The relatively even but low rate of thermal transfer provided by the thermal conductor 920 is represented in the illustrated example by a sparse stippling pattern.

FIG. 10 shows a schematic example of fluid flows and heat exchange in an example heat exchanger module 1000 configured to utilize fluid impingement. In general, fluid impingement occurs when a fluid flow is directed at a confining surface rather than along the surface.

In the illustrated example, a fluid flow 1001 a flows in a first direction 1002 a through a fluid conduit 1010 a. A fluid flow 1001 b flows into a fluid conduit 1010 b through an impingement jet 1012 in a different direction 1002 b such that the fluid flow 1001 b impinges upon a thermal conductor 1020 that separates the fluid flow 1001 a and the fluid flow 1001 b. The thermal conductor 1020 is configured to conduct heat energy between the fluid flows 1001 a and 1001 b.

In the illustrated example, the cross-sectional velocities of the fluid flows 1001 a, 1001 b are represented by a collection of arrows 1030, in which longer arrows represent faster flow and shorter arrows represent slower flows. As a fluid flows along a conduit, drag generally occurs at/near the boundaries between the fluid and the solid walls of the conduit. In the illustrated example, the fluid conduit 1010 a is substantially linear, and has relatively faster flows through its center while having relatively slower flows near the walls, including along the thermal conductor 1020.

In the illustrated example, the portions of the fluid flow 1001 a proximal the thermal conductor 1020 flows relatively slowly, with little interaction with other portions within the fluid flow 1001 a. In order to provide improved thermal transfer (e.g., relative to the example heat exchanger module 900 of FIG. 9 ), the impingement jet 1012 directs the fluid flow 1001 b to impinge upon the thermal conductor 1020 at an impingement point 1040. The impinging flow increases the velocity of fluid that contacts the thermal conductor 1020, and increases the rate of flow along the thermal conductor 1020 near the impingement point 1040. Such impingement also creates turbulence within the fluid flow 1001 b that can cause thermal mixing within the fluid flow 1001 b, disrupting fluid boundary flow conditions, reducing thermal equalization proximal the thermal conductor 1020, and increasing overall heat transfer proximal to the impingement point 1040. As such, the portions of the fluid flows 1001 a, 1001 b proximal the impingement point 1040 can exhibit additional heat transfer capability than can be provided without the use of impingement (e.g., the example heat exchanger module 900). The relative, additional rates of thermal transfer provided by the thermal conductor 1020 are represented in the illustrated example by various stippling patterns, with dense patterns representing areas having relatively higher rates of heat transfer and sparse patterns representing areas having relatively lower rates of heat transfer.

FIG. 11 shows a schematic example of fluid flows and heat exchange in an example heat exchanger module 1100 configured to utilize dual fluid impingement. In the illustrated example, a fluid flow 1101 a flows into a fluid conduit 1110 a in a direction 1102 a through an impingement jet 1112 a such that the fluid flow 1101 b impinges upon a thermal conductor 1120 that separates the fluid flow 1101 a and a fluid flow 1101 b. The fluid flow 1101 b flows into a fluid conduit 1110 b through an impingement jet 1112 b in a direction 1102 b such that the fluid flow 1101 b impinges upon the thermal conductor 1120 at an impingement point 1140. The thermal conductor 1120 is configured to conduct heat energy between the fluid flows 1101 a and 11001 b.

In the illustrated example, the cross-sectional velocities of the fluid flows 1101 a, 1101 b are represented by a collection of arrows 1130, in which longer arrows represent faster flow and shorter arrows represent slower flows. As a fluid flows along a conduit, drag generally occurs at/near the boundaries between the fluid and the solid walls of the conduit.

In order to provide improved thermal transfer (e.g., relative to the example heat exchanger modules 900 and 1000 of FIGS. 9 and 10 ), the impingement jets 1112 a and 1112 b direct the fluid flows 1101 a and 1101 b to impinge upon the thermal conductor 1120 proximal to the impingement point 1140. The impinging flows increase the velocities of fluids that contact the thermal conductor 1120, and increase the rates of flows along the thermal conductor 1120 radiating away from the impingement point 1140. Such impingements also create turbulence within the fluid flows 1101 a and 1101 b that can disrupt boundary flow conditions and cause thermal mixing within the fluid flows 1101 a and 1101 b, reducing thermal equalizations proximal the thermal conductor 1120 and increasing overall heat transfer proximal to the impingement point 1140. As such, the portions of the fluid flows 1101 a, 1101 b proximal the impingement point 1140 can exhibit additional heat transfer capability than can be provided without the use of impingement (e.g., the example heat exchanger module 900) or with the use of single-sided impingement (e.g., the example heat exchanger module 1000). The relative, additional rates of thermal transfer provided by the thermal conductor 1120 are represented in the illustrated example by various stippling patterns, with dense patterns representing areas having relatively higher rates of heat transfer and sparse patterns representing areas having relatively lower rates of heat transfer.

FIG. 12 shows a schematic example of a heat exchanger module 1200 with a collection of fluid impingement ports 1250. In some embodiments, the heat exchanger module 1200 can be a visually simplified model of an embodiment of the example heat exchanger module 200 and the example fluid conduits 220 and 620 defined by the heat exchanger module 200 and the example cavity walls 302 of FIGS. 1-6 . In some embodiments, the heat exchanger module 1200 can be a modification of the example heat exchanger module 700 of FIG. 7 .

The heat exchanger module 1200 includes a fluid conduit 1202 having an inner wall 1203 defined through the axial length of the heat exchanger module 1200 between an inlet 1204 and an outlet 1206. A fluid conduit 1212 is defined through the axial length of the heat exchanger module 1200 between an inlet 1214 and an outlet 1216.

In use, fluids received at the inlets 1204 and 1214 from their respective fluid manifolds flow along the fluid conduits 1202 and 1212 to the outlets 1206 and 1216. The outer wall 1208 is thermally conductive, so while the fluids in the fluid conduits 1202 and 1212 are fluidically isolated from each other by the inner wall 1203 and the outer wall 1208, thermal energy (e.g., heat) is able to pass from one fluid to the other. In the illustrated example, the amount of surface area available for heat transfer is defined by the inner wall 1203 and by the outer wall 1208.

The fluid conduit 1212 is configured with a collection of fluid impingement ports 1250 and supply channels 1251. The configuration of the fluid conduit 1212 causes fluid flowing through the fluid conduit 1212 to take a non-linear, non-laminar path between the inlet 1214 and the outlet 1216. The fluid impingement ports 1250 cause the flow in the fluid conduit 1212 to impinge upon the outer wall 1208 repeatedly to create a collection of impingement points with high thermal transfer, be redirected away from the outer wall 1208 to a subsequent supply channel 1251 (e.g., acting as a drain channel), and then be re-impinged upon the outer wall 1208 by a subsequent fluid impingement port 1250. Eventually, the flow exits at the outlet 1216 (e.g., acting as a drain channel). In some embodiments, the configuration of the fluid conduit 1212 can also provide an increased amount of thermally conductive surface area to further promote heat transfer between the fluid conduits 1202 and 1212.

In some embodiments, the heat exchanger module 1200 can have any appropriate number and arrangement (e.g., axially and/or circumferentially) of the fluid impingement ports 1250. In some embodiments, the selections of inlets, outlets, and directions of flows can implement any appropriate combination. For example, the inlet 1204 and/or the inlet 1214 can be used as outlets, and the outlet 1206 and/or the outlet 1216 can be used as inlets.

FIG. 13 shows another schematic example of another heat exchanger module 1300 with collections of fluid impingement ports. In some embodiments, the heat exchanger module 1300 can be a visually simplified model of an embodiment of the example heat exchanger module 200 and the example fluid conduits 220 and 620 defined by the heat exchanger module 200 and the example cavity walls 302 of FIGS. 1-6 . In some embodiments, the heat exchanger module 1300 can be a modification of the example heat exchanger module 700 or 1200 of FIGS. 7 and 12 .

The heat exchanger module 1300 includes a fluid conduit 1302 having an inner wall 1303 defined through the axial length of the heat exchanger module 1300 between an inlet 1304 and an outlet 1306. A fluid conduit 1312 is defined through the axial length of the heat exchanger module 1300 between an inlet 1314 and an outlet 1316.

In use, fluids received at the inlets 1304 and 1314 from their respective fluid manifolds flow along the fluid conduits 1302 and 1312 to the outlets 1306 and 1316. The outer wall 1308 is thermally conductive, so while the fluids in the fluid conduits 1302 and 1312 are fluidically isolated from each other by the inner wall 1303 and the outer wall 1308, thermal energy (e.g., heat) is able to pass from one fluid to the other. In the illustrated example, the amount of surface area available for heat transfer is defined by the inner wall 1303 and by the outer wall 1308.

The fluid conduit 1302 is configured with a collection of fluid impingement ports 1340 and a collection of supply channels 1341. The fluid conduit 1312 is configured with a collection of fluid impingement ports 1350 and a collection of supply channels 1351. The configurations of the fluid conduits 1302 and 1312 cause fluids flowing through the fluid conduits 1302 and 1312 to take non-linear, non-laminar paths between the inlets 1304, 1314 and the outlets 1306, 1316.

The fluid impingement ports 1340 cause the flow in the supply channels 1341 to impinge upon the inner wall 1303 repeatedly to create a collection of impingement points with high thermal transfer, be redirected away from the inner wall 1303 to a subsequent supply channel 1341 (e.g., acting as a drain channel), and then be re-impinged upon the inner wall 1303. The fluid impingement ports 1350 cause the flow in the fluid conduit 1312 to impinge upon the outer wall 1308 repeatedly to create a collection of impingement points with high thermal transfer, be redirected away from the outer wall 1308 to a subsequent supply channel 1351 (e.g., acting as a drain channel), and then be re-impinged upon the outer wall 1308. Eventually, the flows exit at the outlets 1306 and 1316 (e.g., acting as drain channels). In some embodiments, the configurations of the fluid conduits 1302 and 1312 can also provide increased amounts of thermally conductive surface area to further promote heat transfer between the fluid conduits 1302 and 1312.

In some embodiments, the heat exchanger module 1300 can have any appropriate number and arrangement (e.g., axially and/or circumferentially) of the fluid impingement ports 1350. In some embodiments, the selections of inlets, outlets, and directions of flows can implement any appropriate combination. For example, the inlet 1304 and/or the inlet 1314 can be used as outlets, and the outlet 1306 and/or the outlet 1316 can be used as inlets.

FIG. 14 is a flow diagram of an example process 1400 for heat exchange. In some implementations, the process 1400 can be used with the example modular heat exchanger assembly 100 of FIGS. 1-2 and 6 , and/or the example heat exchanger modules 200, 700, 800 a-800 c, 900, 1000, 1100, 1200, and/or of FIGS. 2, and 5A-12 .

At 1410, a first flow of a first fluid is flowed to a first manifold assembly. For example, fluid can flow through the fluid port 112 a into the example fluid manifold assembly 110 a.

At 1420, the first manifold assembly directs the first flow to at least one modular heat exchanger assembly coupled to the first manifold assembly. For example, the example fluid manifold assembly 110 a can direct fluid received at the fluid port 112 a to one or more of the example heat exchanger modules 200.

At 1430, a second flow of a second fluid is flowed to a second manifold assembly removably coupled to the at least one modular heat exchanger assembly. For example, fluid can flow through the manifold port 114 b into the example fluid manifold assembly 110 b.

At 1440, the second manifold assembly directs the second flow to the at least one modular heat exchanger assembly. For example, the example fluid manifold assembly 110 b can direct fluid received at the manifold port 114 b to one or more of the example heat exchanger modules 200.

At 1450, the first flow flows through a first fluid conduit of the modular heat exchanger assembly, from the first manifold assembly to the second manifold assembly. For example, fluid received at the fluid port 112 a can flow through the example fluid conduits 220, 702, 910 a, 1010 a, 1110 a, 1202, or 1302 to the fluid manifold assembly 110 b and the fluid port 112 b.

In some implementations, flowing, through the first fluid conduit of the modular heat exchanger assembly, the first flow from the first manifold assembly to the second manifold assembly can include flowing the first flow through one or more supply channels of the first fluid conduit, flowing the first flow through a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and flowing the first flow through a collection of drain channels of the first fluid conduit, away from the thermal conductor. For example, fluid can flow through the example supply channel 1251 to the fluid impingement port 1250, where the flow becomes directed at the outer wall 1208, and then flows out to a subsequent supply channel 1251 or to the outlet 1216.

At 1460, the second flow flows through a second fluid conduit of the modular heat exchanger assembly, from the second manifold assembly to the first manifold assembly. For example, fluid received at the fluid port 112 b can flow through the example fluid conduits 620, 712, 910 b, 1010 b, 1110 b, 1212, or 1312 to the fluid manifold assembly 110 b and the manifold port 114 a. In some implementations, flowing, through the second fluid conduit of the modular heat exchanger assembly, the second flow from the second manifold assembly to the first manifold assembly can include flowing the second flow through one or more supply channels of the second fluid conduit, flowing the second flow through a collection of impingement jets configured to direct fluid flow to impinge upon the thermal conductor, and flowing the second flow through a collection of drain channels of the second fluid conduit, away from the thermal conductor. For example, fluid can flow through the example supply channel 1341 to the fluid impingement port 1340, where the flow becomes directed at the inner wall 1303, and then flows out to a subsequent supply channel 1341 or to the outlet 1306.

At 1470, a thermal conductor conveys heat energy between the first fluid and the second fluid. For example, heat energy may be conveyed between fluids by any one or more of the body 202, the inner wall 703 and the outer wall 708, the thermal conductors, 920, 1020, or 1120, the inner wall 1203 and the outer wall 1208, or the inner wall 1303 and the outer wall 1308.

In some implementations, the process 1400 can also include assembling the modular heat exchanger assembly to the first manifold assembly, fluidically connecting, based on the assembling, the first fluid conduit to a first manifold of the first manifold assembly, fluidically connecting, based on the assembling, the second fluid conduit to a second manifold of the first manifold assembly, assembling the modular heat exchanger assembly to the second manifold assembly, fluidically connecting, based on the assembling, the first fluid conduit to a third manifold of the second manifold assembly, and fluidically connecting, based on the assembling, the second fluid conduit to a fourth manifold of the second manifold assembly. For example, the example heat exchanger modules 200 can be inserted into the cavities 300 of the heat exchanger portion 130, and the assembled heat exchanger portion 130 can be assembled to the fluid manifold assemblies 110 a and 110 b. When assembled, the example modular heat exchanger assembly 100 defines fluid paths that fluidically connect the fluid ports 112 a and 112 b through the heat exchanger modules 200, and fluidically connect the manifold ports 114 a and 114 b through the heat exchanger modules 200.

In some implementations, the process 1400 can include directing, by a collection of seals configured to separate the first flow from the second flow, leakage of one of the first flow or the second flow past at least one of the collection of seals away from the other of the first flow or the second flow and toward a drain. For example, fluid leakage that manages to get past the example seal assemblies 612 flows out the drain channels 614.

Although a few implementations have been described in detail above, other modifications are possible. For example, the logic flows depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flows, and other components may be added to, or removed from, the described systems. Accordingly, other implementations are within the scope of the following claims. 

What is claimed is:
 1. A heat exchanger module comprising: a tubular housing; a first fluid conduit; a second fluid conduit, fluidically isolated from the first fluid conduit; a thermal conductor configured to convey heat energy between the first fluid conduit and the second fluid conduit; a first fluid connector assembly, the first fluid connector assembly comprising: a first fluid port fluidically connected to the first fluid conduit; and a second fluid port fluidically connected to the second fluid conduit; and a second fluid connector assembly, the second fluid connector assembly comprising: a third fluid port fluidically connected to the first fluid conduit; and a fourth fluid port fluidically connected to the second fluid conduit.
 2. The heat exchanger module of claim 1, wherein the first fluid conduit is a first tubular conduit defined within the tubular housing, and the second fluid conduit is a second tubular conduit defined concentrically within the first fluid conduit.
 3. The heat exchanger module of claim 1, wherein the first fluid conduit comprises: one or more supply channels; a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and one or more drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the third fluid port.
 4. The heat exchanger module of claim 1, wherein the second fluid conduit comprises: one or more supply channels; a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and one or more drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the fourth fluid port.
 5. The heat exchanger module of claim 1, further comprising at least one fluid connector assembly comprising: a first fluid port fluidically connected to the first fluid conduit; a second fluid port configured fluidically connected to the second fluid conduit; and a seal assembly comprising an interface defining a first fluid seal arranged between the first fluid port and the second fluid port.
 6. The heat exchanger module of claim 5, further comprising a second fluid seal defined between the first fluid port and the second fluid port, wherein: a first fluid connector assembly is configured to removably connect to a first fluid coupler of a first manifold assembly, to fluidically connect the first fluid conduit to a first fluid manifold of the first manifold assembly and to connect the second fluid conduit to a second fluid manifold of the first manifold assembly; and a second fluid connector assembly is configured to removably connect to a second fluid coupler of a second manifold assembly, to fluidically connect the first fluid conduit to a third fluid manifold of the second manifold assembly and fluidically connect the second fluid conduit to a fourth fluid manifold of the second manifold assembly.
 7. The heat exchanger module of claim 6, wherein the first manifold assembly defines an overboard fluid path fluidically connecting a cavity between the first fluid seal and the second fluid seal of the first fluid connector assembly to a fluid drain.
 8. The heat exchanger module of claim 6, wherein the second manifold assembly defines an overboard fluid path fluidically connecting a cavity between the first fluid seal and the second fluid seal of the second fluid connector assembly to a fluid drain.
 9. A modular heat exchanger assembly comprising: a first manifold assembly comprising a first manifold and a second manifold; a second manifold assembly comprising a third manifold and a fourth manifold; and at least one heat exchanger module configured to removably engage the first manifold assembly and the second manifold assembly and comprising: a tubular housing; a first fluid conduit; a second fluid conduit, fluidically isolated from the first fluid conduit; and a thermal conductor configured to convey heat energy between the first fluid conduit and the second fluid conduit.
 10. The modular heat exchanger assembly of claim 9, wherein the first manifold assembly comprises a first manifold fluid port fluidically connected to the first manifold and a second manifold fluid port fluidically connected to the second manifold.
 11. The modular heat exchanger assembly of claim 9, wherein the heat exchanger module further comprises a fluid connector assembly, the fluid connector assembly comprising: a first fluid connector assembly, the first fluid connector assembly comprising: a first fluid port fluidically connected to the first fluid conduit and configured to fluidically connect the first fluid conduit to the first manifold assembly; and a second fluid port fluidically connected to the second fluid conduit configured to fluidically connect the second fluid conduit to the second manifold assembly; and a second fluid connector assembly, the second fluid connector assembly comprising: a third fluid port fluidically connected to the first fluid conduit and configured to fluidically connect the first fluid conduit to the third manifold; and a fourth fluid port fluidically connected to the second fluid conduit configured to fluidically connect the second fluid conduit to the fourth manifold.
 12. The modular heat exchanger assembly of claim 11, wherein the first fluid connector assembly defines a first seal defined between the first fluid port and the second fluid port, and the first manifold assembly defines a first overboard fluid path fluidically connecting a first cavity defined between the first seal, the second fluid conduit, and the first manifold assembly to a first drain.
 13. The modular heat exchanger assembly of claim 12, further comprising a second seal defined between the first fluid port and the second fluid port, wherein the second fluid connector assembly defines a third seal and a fourth seal arranged between the third fluid port and the fourth fluid port, and the second manifold assembly defines a second overboard fluid path fluidically connecting a second cavity defined between the third seal, the fourth seal, the second fluid conduit, and the second manifold assembly to a second drain.
 14. The modular heat exchanger assembly of claim 9, wherein the first fluid conduit is a first tubular conduit defined within the tubular housing, and the second fluid conduit is a second tubular conduit defined concentrically within the first fluid conduit.
 15. The modular heat exchanger assembly of claim 9, wherein the first fluid conduit comprises: one or more supply channels; a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and a plurality of drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the third manifold.
 16. The modular heat exchanger assembly of claim 9, wherein the second fluid conduit comprises: one or more supply channels; a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and a plurality of drain channels configured to direct fluid flow away from the thermal conductor and toward a subsequent supply channel or to the fourth manifold.
 17. A method of heat exchange, the method comprising: flowing a first flow of a first fluid to a first manifold assembly; directing, by the first manifold assembly, the first flow to at least one modular heat exchanger assembly coupled to the first manifold assembly; flowing a second flow of a second fluid to a second manifold assembly removably coupled to the at least one modular heat exchanger assembly; directing, by the second manifold assembly, the second flow to the at least one modular heat exchanger assembly; flowing, through a first fluid conduit of the modular heat exchanger assembly, the first flow from the first manifold assembly to the second manifold assembly; flowing, through a second fluid conduit of the modular heat exchanger assembly, the second flow from the second manifold assembly to the first manifold assembly; and conveying, by a thermal conductor, heat energy between the first fluid and the second fluid.
 18. The method of claim 17, wherein flowing, through the first fluid conduit of the modular heat exchanger assembly, the first flow from the first manifold assembly to the second manifold assembly further comprises: flowing the first flow through one or more supply channels of the first fluid conduit; flowing the first flow through a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and flowing the first flow through a plurality of drain channels of the first fluid conduit, away from the thermal conductor.
 19. The method of claim 17, wherein flowing, through the second fluid conduit of the modular heat exchanger assembly, the second flow from the second manifold assembly to the first manifold assembly further comprises: flowing the second flow through one or more supply channels of the second fluid conduit; flowing the second flow through a plurality of impingement jets configured to direct fluid flow to impinge upon the thermal conductor; and flowing the second flow through a plurality of drain channels of the second fluid conduit, away from the thermal conductor.
 20. The method of claim 17, further comprising: assembling the modular heat exchanger assembly to the first manifold assembly; fluidically connecting, based on the assembling, the first fluid conduit to a first manifold of the first manifold assembly; fluidically connecting, based on the assembling, the second fluid conduit to a second manifold of the first manifold assembly; assembling the modular heat exchanger assembly to the second manifold assembly; fluidically connecting, based on the assembling, the first fluid conduit to a third manifold of the second manifold assembly; and fluidically connecting, based on the assembling, the second fluid conduit to a fourth manifold of the second manifold assembly.
 21. The method of claim 17, further comprising directing, by a plurality of seals configured to separate the first flow from the second flow, leakage of one of the first flow or the second flow past at least one of the plurality of seals away from the other of the first flow or the second flow and toward a drain. 